Preparation of phosgene



une L11, i948.

E. GORIN ETAI..

PREPARATION oF PHosGENE Filed Aug. 13, 1945 SYSTEM FF/@g 32' Ever 3/ 6o a w 27 Il 30 l as by-product hydrogen chloride.

atented June 29, 1948 PREPARATION F PHOSGENE Everett Corin and Charles Burke Miles, Dallas, by mesne assignments, to 0il Company, Incorporated,

a corporation of New York Tex., assignors, Socony-Vacuum New York, N. Y.,

Application August 13, 1945, Serial No. 610,606 9 Claims. (Cl. 26o-544) This invention relates to an improved method for the production of phosgene from carbon monoxide, hydrogen chloride and air. More particularly this invention is concerned with a continuous process whereby hydrogen chloride by-product from organic synthesis processes utilizing phosgene as an intermediate may be reconverted to said phosgene intemediate. In a more narrow sense this invention is concerned with a process whereby phosgene is produced by the interaction of carbon monoxide with cupric chloride.

Phosgene is acquiring ever-increasing use as an intermediate in the synthesis of organic chemicals. In many of these processes, part or all of the chlorine content of the phosgene is liberated Examples of such processes include the reactions of phosgene with alcohols to produce dialkyl carbonates and alkyl chlorocarbonates, the reactions of phosgene with olens to produce unsaturated acid chlorides and acids and the reactions of phosgene with paraiiins to produce ketones and acid chlorides.

An object of the present invention is to produce phosgene from carbon monoxide, hydrogen chloride and air. Still another object of the invention is to utilize lay-product hydrogen chloride for the production of phosgene intermediate in processes wherein the use of phosgene intermediate results in the production of by-product hydrogen chloride. A further object of the invention is to provide an integrated continuous process for the conversion of cuprous chloride to cupric chloride utilizing lay-product hydrogen chloride and air for. this initial step of the process and in a second step reacting the cupric chloride produced in said rst step with carbon monoxide to produce phosgene. Other objects of the invention will become apparent from the description thereof which follows.

The process is essentially operated in two major steps comprising an oxidation-neutralization step and a chlorination step. The reaction occurring in the oxidation-neutralization step is essentially that described by the equation (l) CuC12+2HCl l/2O2- 2CuC`l2-1H2O The reaction occurring in the chlorination step is essentially that described by the equation ycontinuously circulating media to transfer the copper chloride chlorine carrier to and from the phosgene producing reaction zone. It is preferred to transfer and contact the copper chlorides with the gaseous reactants by means of highly porous refractory supports such as activated alumina. silica gel or acid treated clays in the form of finely divided particles of size less than mesh and larger than 300 mesh, preferably 100 mesh to 200 mesh particle size. These refractory supports are impregnated with copper salts, as by immersing the powdered material in the molten salt, permitting the mixture to solidify, grinding the mass of porous solid supported copper chloride, and classifying to obtain the particle size of agent desired. By the term agent as used inthe specification and claims is meant the copper chloride together with alkali metal chlorides. if any, plus the porous solid support thereof.

A preferred method for preparing the agent is to submit the refractory supporting material to a succession of alternate digestion and drying steps wherein solutions of the copper salts are used to superimpose successive increments of the copper salts on the support. Following the final drying step the mass of supported chloride or chlorides of copper is crushed and classified to give the desired range of particle size agent. The agent employed when the copper salt is in the cupric form ,should contain from 10 to 30 per cent by weight of copper, preferably from to parts by weight of copper on the supporting refractory material. If desired the impregnating salt may contain from 20 to 40 mol per cent, Ipreferably to 30 mol per cent of an alkali metal chloride such as potassium chloride. But in no case when alkali metal salt is present should the amount of impregnated salt exceed to 65 per cent by weight of the total agent since the alkali metal salt lowers the melting point of the impregnating salt and packing of impregnated powder will result at higher concentration of salt in the agent, with a resulting interference with the powder transfer and contact with reactant gases. The presence of the alkali metal chloride, i. e., potassium chloride, catalyzes the oxidation of cuprous chloride and also reduces the volatility of cupric chloride in the chlorination step.

Contact of the copper chlorides with reactant gases is made by hindered settling technique or if desired the impregnated support may be in the form of larger particles of size within the range of from about 2 mesh to about 20 mesh in which case contact with the reactant gases is made by countercurrent ow of the impregnated support flowing by gravity counter to an ascending stream of said gases. However, it is preferred to operate with nely divided agent in hindered settling type operation as described in detail hereinbelow.

Referring now to the figure which represents diagrammatically an -apparatus and the preferred method of operating the invention, tower I is a combination reactor which is divided into four reaction chambers II, I2, I3 and I4, chambers II, I2, and I3 being utilized as the oxidation# neutralization section of the tower and chamber I4 functioning as the chlorination or main reaction zone wherein the carbon monoxide is converted to phosgene. The oxidation-neutralization section of tower I0 is divided into the three separate reaction zones in order to obtain countercurrent flow of oxygen containing gas and hydrogen chloride gas against chlorine depleted copper chloride agent which is delivered to reactor II from cyclone separator I5 by means of dip leg I6. standpipes I1, I8 and I9 are provided for transfer of the agent from reactor II to reactor I2, from reactor I2 to reactor I3, and from reactor I3 to reactor I4 respectively. As the powdered agent is put into a state of hindered settling by the upiiowing reactant gases as described hereinbelow, the agent overflows into the standpipes. The bulk density of the agent in the standpipes is controlled by valves 20, 2|, and 22 to a greater density than the hindered settled agent in the respective reactors from which the agent overflows and the agent is caused to flow in stages in a fluid-like stream from re actor II to reactor I4. The agent in standpipes I1 and I8 is fluidized by a relatively small amount of air injected to the standpipes via lines 23 and 24 respectively. The agent in standpipe I9 is iluidized by hydrogen chloride gas injected thereto via line 25.

The chlorination reaction zone I4 is provided with standpipe 26 which may be centrally located as indicated or it may be located near the inside wall of reactor I4. As the partially dechlorinated reagent is maintained in a hindered settling state, the reagent overflows into standlpipe 26 and settles therein as a mass having a higher bulk density than the -agent in the main body of reactor I4. The flow of agent downward through thestandpipe 26 is regulated by valve 21, and the agent is uidized therein by means of a small stream of carbon monoxide introduced to this standpipe via line 28 which leads from -the main carbon monoxide feed line. standpipe 26 is equipped with heat exchanger 29 wherein the hot partially dechlorinated agent is cooled to a temperature below about 400 C. by heat exchange with the carbon monoxide feed stream to the phosgene producing reactor I4.

Relatively cold oxygen depleted air in line` 30 is picked up by multistage. blower 3l and is passed through injector 32 where the air picks up dechlorinated agent from the base of standpipe A2li. The agent is lpreferably only partially dechlorinated, and the cupric content of the agent in standpipe 26 should be Within the range of from about 35 to 45%, wlththe balance reduced to cuprous copper. The air at a pressure in excess of the pressure in reactor I4 carries the agent through line 33, heat exchanger 34 and line 35 to cyclone separator I5. The agent separated in I5 may be delivered to a hopper, not shown in the drawing, which feeds the same to reactor II or the agent may bedelivered, as shown, directly to reactor II by meansof dip leg I6. If desired, heat exchanger 34may be eliminated, QQQling 0f the carrier gas being accomplished by means of cooler 35 in carrier gas recycle line 31 which leads to blower feed line 30. As the carrier gas is continuously recycled through lines 30, 33, 35 and 31, it becomes more depleted with respect to oxygen content as a result of the tendency to oxidize the cuprous chloride content of the agent to cupric oxychloride. Makeup air to replace the oxygen removed from the carrier gas by line oxidation of the agent is introduced to line 30, from an external source as shown.

The agent at a temperature within the approximate range of 320 C. to 350 C. is delivered to reactor II at a pressure within the range of from about 5 atmospheres to about 10 atmospheres. Air in line 40 is picked up by multistage blower or compressor 4I and passed in part through line 42 to coil 43 in exchanger 34 where it is preheated to a temperature preferably above 300 C. The air is passed through line 44 to air distributing plate 45 at the base of reactor II. The remainder of the air in line 42 is passed through coil 46 for pickup of heat and thence by lines 41 and 48 to distributing plate 49 in reactor I3. Hydrogen chloride at a pressure of 5 to 10 atmospheres is introduced to the process by means of a multistage blower 50 in line 5I which connects with line 48. Thus, a mixture of oxygen containing gas, such as air, and hydrogen chloride is delivered to reactor I3 by means of distributing Iplate 49. The mol ratio oi hydrogen chloride to total oxygen introduced to reactors II and I3 should be within the range of 4 to 1 and 6 to 1. In case a part of the oxygen is introduced to reactor I I, the ratio of hydrogen chloride to oxygen in the mixed gases introduced to reactor I3 is at least 4 to 1. If desired, all of the air may be passed through coil 46 and lines 41 and 48 leading to reactor I3, the oxidation of the agent in reactor II being accomplished by residual oxygen in the gas leaving reactor I2. However, it is preferred to introduce a part of the air directly to reactor II in order to insure preoxidation of the agent prior to contact with hydrogen chloride as hereinafter described.

The temperature of the agent as it enters reactor II will usually be within the range of from about 320 C. to about 345 C. and as the power is fluidized by the air ascending from plate 45, the temperature rises rapidly due to the exothermic heat of conversion of the cuprous chloride of the agent to cupric oxychloride. The tem*- perature of the partially oxidized agent as it overows into standpipe I1 will be within the range of from about 350 C. to about 375 C. and the average cupric content of the copper salt components of the agent will be raised in reactor II about 9 p'er cent, i. e., from -a range of 35 to 45% as the agent enters the reactor to a range of 44 to 54% as the agent overflows into standpipe I1. Reactor II which may be designated as the primary oxidation zone is operated at a pressure within the range of 5 to 10 atmospheres, the pressure being less than the pressures in reactors I2, I'3 and I4. The depth of fiuidized bed ih reactor II is suitably Within the range of from about 8 to about 12 feet, preferably about 10 feet. The average residence time of the agent in reactor II usually will be within the range of from about 20 seconds to about 90 seconds While the mean residence time of the oxidizing gas in the uidized mass of agent ordinarily will be within the range of from about 3 to about 12 seconds. The linear velocity of the upfiowing gas in reactor II will be correspondingly within the range of from` about 1 foot to 4 fet'per'second... The gas, partially spent with respect to oxygen content, passes from reactor II through line 2 to' cyclone separator 53. Separated agent is returned to reactor II through dip leg 54 and the oxygen depleted airis passed from the process via line 55." Dip legs 54 and I6 are' aerated by means of air introducedthereto above the in'dicated valves in said dip legs.

Reactor I2 is designated as the secondary oxidation zone or the primary neutralization zone' sincein this zone the oxidized agent rst con'- tacts hydrogen chloride which enters reactor I2 through the bubble capped perforated plate whichseparates reactor I3 'from reactor I 2. As the oxidized. agent flows from standipipeH into reactorflls at1 a temperature within the range oidroni about 350 C. to about 375 Q. it isl fluid# ized bythe residual gas from'reactor I3 contain# ing nitrogen.. oxygen and hydrogen chloride whichescape reaction in I3 and any chlorine formed'by the oxidation of hydrogen chloride in reactorl. The residence times of this residual gas-and` of the agentin reactor I2 approximates the corresponding residence times of gas and agent in reactor II and 'theaverage cupric con tent increases from arange of 44-54% to a range of from about-64 to 74% cupric copper -based on the-total copper in the agent as the average temper'ature ofthe uidized mass increases from the range of 35o-375 Cito the range of from about 420-445 C. The agent overflows V-into standpipe IB. -The residual gas from reactor I2 containing predominantly nitrogen, small amounts of oxygen and -a-trace of hydrogen chloride passes upward through the ybubble capped openings in the plate atthe bottom of reactor I Il wherein ythe last traces of hydrogen chloride are removed byneutralization of the copper oxychloride. If all of the oxygen containing gas is introduced to the cupric chloride regeneration s tep through coil 46 and lines 41 and 48, the oxygen content of the gas entering reactor II from reactor I2 will be much higher-and this oxygen is removed in large part by the oxidation of the cuprous chloride in the agent. 1

In reactor I3, which is primarily a neutraliza tion zone, the agent delivered via standpipe I8 isiluidized in hindered settling operation, -the conversion of the cupric oxychloride of the agent to cupric chloride being substantially completed in this-zone. The cupric chloride of the copper chloride content of the agent is raised from the range of 64-74% to the range of 8595% inreactor I3 by the action of the mixture of air and hydrogen chloride in the iluidizing gas introduced 4 by distributing plate 49 as described hereina'bove.

The depth of the uidized bed in reactor I3 is somewhat -greater than in reactors II and I2, thus permitting a longer contact time of the reactant gas with the uidized agent.` Thus, the range of depth of hindered flow reactant rbed is from about 10 feet to about 16 feet, preferably about 13 or 14 feet in reactor I3. The average contact time of the gas with the agent is Within the range of 2 to about 20 seconds while the average residence time of the agent in reactor I3 is within the range of from about 45 to about 360 seconds, preferably about 100 seconds. The reaction of hydrogen chloride with cupric oxychloride to fform cupric chloride is highly exothermic and hence Ithe temperature of the agent is increased from the range of 420.C.-445 C. to the range of 500 C.-525 C. as the fluidized agent overows into standpipe I9. As indicated hereinabove; reactor 'Isis operated'under a' pressure of from 5 to 10 atmospheres'and hence 'decomposi lpassing through `the three stage cupric chloride'- regeneratio'n zone the cupric copper. content 'of the 'agent is increased from a range of :i5-45% cupric copper to 8595% cupric copper while 'the temperature ofthe agent is raisedirom a range of 32o-3454 C. to a range of 500-525 C. for delivery via' standpipe I9 to the phosgen'e producing reactor I4. v

Carbon monoxide in line 60"is picked up by' lmeans of multistage blower or compressor 6I 'and is passed through line 62 to heat exchanger 29 where'it i's heated by the partially dechlorinat'ed' agent from standpipe 26. From exchangerfz! the carbon monoxide is' passed through-line 63"' through heat-in-gcoil 6I in furnace 65 and thence through line 66 to distributor-coil 81 at the base lof rea'ctor I4. 'As the carbon monoxide is'forced into reactor I4 the cupric chloride enriched agent is fluidized to a depthof from about 35 to 50 feet.' preferably about' 40' feet and the average cupric copper content of the agent is reduced from the rangel of 85-95% to about'the range 35 to 45% cupric copper. The carbon monoxide 'is converted to 'phosgene and a smallamount of free chlorine is-also produced.

The reaction of cupric vchloride with carbon monoxide* to form phosgene is slightly endothermlc and! hence heat .must be -supplied to reactor I4 to maintain v.the temperature 'of the agent above 475 C. and preferably-in the range of 500 C. to 525 C. A temperature in reactor I4 of at least 500 C. is -preferred in order to'obtai'n economic conversion rates at residence times of the carbon monoxide within the range designated hereinbelow. `This may be accomplished in one fr all of three ways. For example, the temperature-of the'agent may be allowed to build up suf' ciently-in the cupric chloride regeneration step in reactors I2 and I3 as described above in orderto store heat in the agent. This method, if used exclusively,-has the disadvantage of decomposing the cupric chloride and/or vaporizing the copper salts lfrom the agent in the regeneration step.

.Hence,.the above temperature range limitation isset for the agent transferred from reactor I3 perature 0f-s25c. to 650 C. in furnace 65. The4 exclusive use of this method is not desirable due to the excessive amount of heating surface required in heating coil 64 and it is desirable to limit the preheat temperature of the carbon monoxide feedl to the range of 500 C.550 C. A third method, which is illustrated in the drawing, is to circulate a heat transfer medium such as a molten metal or an eutectlc salt mixture through rcoils in furnace '65 and thence through coils immersed in the fluidized agent in reactor I4 to furnish lby direct heat transfer the necessary heat to maintain the temperature oef the agent above about 500 C. in I4'. Thus, aliquid heating medium is introduced from line 10.1eading to line 1I. Iby means of pump 'I2 and theliquid is circulated through coil 13 in furnace 65 and thence through line 14 and coil 15 which -mospheres designated hereinabove.

and the carbon monoxide must then be preheated to a temperature in excess of 550 C. On the other hand, if agent is introduced to reactor I4 in the range of 475 C.-500 C. it becomes desirable to supply heat by means of coil 15.

The contact time of the carbon monoxide in reactor I4 is preferably wi-thin the range of from about 1 minute to about 6 minutes to give a conversion per pass of carbon monoxide to phosgene of from 15% to 30%. A relatively low linear velocity of carbon monoxide through the iluidized mass is desirable in order to maintain as long contact time in the above range as is compatible with maintenance of eicient hindered settling. Linear velocities within the range of from about 0.2 -foot to 0.5 foot per second are used in reactor I4, preferably from albout 0.3 -foot to about 0.4 footy per second. Higher linear velocities, generally greater than 0.5 foot per second are used in reactors II, I2, and I3.

The relatively high temperatures prevailing in reactor I4 cause some vaporization of copper salts. However, the loss of copper salts from the agent isminimized by operating reactor I4 in the upper part of the range of from 5 to 10 at- The gas from the iluidized mass in reactor I4 which consists of unreacted carbon monoxide, phosgene, a small amount of chlorine, a small amount of volatilized copper chlorides and also some suspended agent passes through valved line to dust chamber 0I. Relatively cold cupric chloride depleted agent is injected into the gas stream in` line 80 through standpipe 82 leading from cyclone separator I or from the hopper (not shown) into which cyclone separator I5 delivers agent. Agent in standpipe 82 is aerated with a small amount of oxygen depleted air introduced above control valve 83 through line 84. The gaseous product stream containing suspended agent is further cooled to a temperature in the range of from about 275 C. to 375 C. by cooling coil B5 in chamber 00. The copper salt is selectively adsorbed on the agent which then settles into standpipe 06, fiuidized by means of carbon monoxide introduced thereto, at a point above valve 81, through line l0 and the agent carrying the absorbed copper salt passes back to reactor I4 thus being retained in the system. The gaseous product carrying a part of the suspended solid passes overhead from chamber 8i through line 09 to cyclone separator 90 whence separated agent is returned to reactor I4 through carbon monoxide fiuidized dip leg SI. The overhead product gas from separator 90 passes through line 92' to the phosgene recovery system 93 where the gas is cooled to normal atmospheric temperature and is recovered, for example, by absorption in a. countercurrent stream of a suitable solvent for the phosgene such as xylene, a kerosene fraction or a chlorinated hydrocarbon such as ethylene dichloride. The nonabsorbed gas comprising carbon monoxide and a major part of the chlorine is recycled Lto reactor I4 through line 94 which connects with carbon monoxide feed line 60. The recycled chlorine combines directly with carbon monoxide to form phosgene under the above conditions of operation of reactor I4 and hence does not accumulate in the carbon monoxide conversion cycle. The solution of phosgene obtained in the phosgene recovery system is stripped to recover phosgene containing a trace of chlorine which product is withdrawn from the process through line 95.

The operation of reactor I4 is illustrated by the following example: 1,380,000 poundsper day of 120 mesh to 200 mesh agent containing 20 grams of copper per 100 grams of agent, of which copper 93% is in the form of cupric chloride, are uidized in hindered settling operation by 1,728,- 000 cubic feet of carbon monoxide measured at standard conditions but introduced to reactor'-I4 at a pressure of 6.6 atmospheres and at an average temperature of 500 C. in a reactor of 6 feet inside diameter, the depth of the fiuidized bed being approximately 40 feet. The linear velocity of the carbon monoxide in the iluidized bed under these conditions of operation is about 0.4 foot per second. The cupric copper content of the agent is reduced from 93 per cent in the feed to an average 43 per cent in standpipe 26 and there is produced a gaseous product containing about 22 mol per cent phosgene and about 5 mol per cent chlorine at the rate of approximately 110,000 pounds of phosgene per day.

In the above description of the process the agent consists of a porous refractory solid impregnated with copper salts alone. However, as indicated hereinabove it may be desirable to operate with an alkali metal chloride such as potassium chloride incorporated with the copper chlorides on the refractory carrier in which case the temperature in reactor I3 is maintained at a lower level, i. e., in the range of from about 465 C. to about 485 C. Residence times of the gases and agent in the reactors are approximately the same as used when the potassium chloride is not a component of the agent. The temperature in reactor I4 is maintained at about 500 C. We have found the reaction in reactor I4 to be substantially thermo neutral in the presence of potassium chloride, and hence the only heat requirement in reactor I4 is the heat necessary to replace the heat lost by radiation and also the heat necessary to raise the temperature of the agent from the range of 465-485 C. to the range of 500 C.-525 C. This temperature can be maintained by preheating the carbon monoxide and by the addition of less heat via coil 15. The cupric content of the copper chloride in the agent as it enters reactor I4 should preferably be within the range of to 90 per cent. The agent should contain above 55 per cent cupric copper as it leaves reactor I4. Thus, a smaller change in cupric'concentration Vis advisable when using the potassium chloride activated agent.

The process may also be operated at pressures below the above operating range, that is, at pressures only slightly above atmospheric pressure. However, economical conversion rates of carbon monoxide to phosgene by the use of cupric chloride impregnated agent is favored by super atmospheric pressure operation. Higher pressures than 10 atmospheres are advantageous, the pressure of operation being limited primarily by the apparatus and type of contacting process employed. Although we prefer to operate reactor I4 at temperatures within the range of 500 C. to 525 C., We do not wish to be limited to this range. For example, We may operate this reactor at temperatures up to 550 C. Higher pressures than 10 atmospheres are usually desirable when operating at temperatures above 525 C. in order to minimize volatilization of the copper salts. High pressure operation is desirable since a high ratio of phosgene to chlorine in the product gas may be maintained and higher throughput for a given reactor size is possible if high pressures are used in reactor I4.

The process described above is adiabatic to the extent that the heat generated in the oxidation of by-product hydrogen chloride is utilized in a. unitary coordinated process for the production of phosgene. The process is particularly adaptable for the production of phosgene intermediate in those chemical processes wherein the use of phosgene intermediate results in the production of large volumes of by-product hydrogen chloride.

While the preferred embodiment of the invention has been described, itis understood that this illustration is only by way of example and that many other modifications and alternative processes fall within the scop'e of the invention.

We claim:

1. A process for the manufacture of phosgene comprising the steps of (1) contacting in a reaction zone a mixture of the chlorides of copper comprising a major proportion of cupric chloride and a minor proportion of cuprous chloride disposed on a porous refractory carrier at a temperature Within the range of from about 500 C. to about 525 C. and at a pressure within the range of from about ve atmospheres to about ten atmospheres with an amount of carbon monoxide in excess of that required to react with said cupric chloride to form a gaseous product comprising phosgene and unreacted carbon monoxide, (2) recovering phosgene from the gaseous product of step 1, (3) heating the residue gas from step 2 comprising carbon monoxide to a temperature in excess of 525 C. to supply heat in the reaction zone of step 1, and (4) recycling the heated residue gas of step 3 to step 1 of the process.

2. A continuous process for the manufacturing of phosgene comprising the steps of (1) continuously passing an oxygen containing gas in contact with a cuprous chloride containing contact mass in a reaction zone to convert at least a part of said cuprous chloride to cupric oxychloride, (2) continuously contacting the oxidized contact mass from step l with a mixture of an oxygen containing gas and hydrogen chloride while controlling the resultant exothermic reaction to prevent the temperature from exceeding 525 C. in at least one reaction zone separate from the reaction zone of step 1 to produce additional cupric oxychloride in said contact mass and to convert the cupric oxychloride therein to cupric chloride, (3) continuously contacting the cupric chloride containing mass of step 2 in a third reaction zone directly without intermediate cooling with an amount of carbon monoxide in excess of that amount required to react with said cupric chloride at a temperature Within range of from 500 C. to 525 C. and at a pressure within the range of from 5 to 10 atmospheres to form a gaseous mixture comprising phosgene, chlorine and carbon monoxide and to form a cuprous chloride enriched contact mass, (4) continuously circulating the cuprous chloride enriched contact mass of step 3 to step 1, (5) fractionating the gaseous reaction product of step 3 to produce a phosgene fraction and a residual gas fraction, and (6) continuously circulating said residual gas fraction from step 5 to step 3 of the process.

3. The process of claim 2 wherein residual gas recovered in step 5 is heated before being circulated to step 3 of the process.

4l. The process as described in claim 2 wherein the cupric copper content of the mass of step 3 amounts to at least 85% of the total copper in said mass.

5. A continuous process for the manufacture Aof phosgene from hydrogen chloride, carbon inonoxide and air comprising the steps of (1)"continuously contacting in a reaction zone porous refractory solid supported cuprous chloride reactant with a gaseous mixture comprising a.V

ing the supportedreactant of step 1 to. 'and through at least on\e separate reaction zone in contact with a gaseous mixture of air and hydrogen chloride to augment the extent of Aconversion of said cuprous chloride to cupric oxychloride and to increase the conversion ofthe cupric oxychloride to cupric chloride, (3) continuously passing the residual gas from step 2 toA step 1, (4) continuously passing the supported reactant of step 2 to and through a third reaction zone in contact with an amount of carbon monoxide in excess of that amount required tovreavt with ihe cupric chloride formed in steps 1 'and 2 and at a temperature within the range o `from 475 C. to 525 C. to form a gaseous mixture comprising phosgene, chlorine and carbon monoxide and to form a cuprous chloride enriched contact mass, (5) continuously circulating the cuprous chloride enriched contact mass of step 4 to step 1, (6) fractionating the gaseous mixture of step 4 to produce a phosgene fraction and a residual gas fraction, and (7) continuously circulating said gas fraction from step 6 to step 4 of the process.

6. A continuous process for the manufacture of phosgene from hydrogen chloride, carbon monoxide and oxygen which comprises the steps of (l) introducing a contact mass comprising a major portion of cuprous chloride and a minor portion of cupric chloride supported on a porous refractory carrier into at least one reaction zone at a temperature above about 320 C.. (2) contacting the supported cuprous chloride in said at least one reaction zone rst with an oxygen containingA gas to convert at least a part of the cuprous chloride to cupric oxychloride and then with a mixture of oxygen containing gas and hydrogen chloride to convert additional cuprous chloride to cupric oxychloride and to convert the cupric oxychloride therein to cupric chloride while controlling the exothermic reaction to prevent the temperature from exceeding 525 C., (3) transferring the cupric chloride enriched contact mass from step 2 and introducing it directly without intermediate cooling into a separate reaction zone, (4) contacting the contact mass in said separate reaction zone with carbon monoxide while maintaining a temperature Within the range of from 475 C. to 525 C. and a pressure within the range of 4from about 5 to about 10 atmospheres to form phosgene and to reduce at least a substantial portion of the cupric chloride in the contact mass to cuprous chloride, (5) continuously recycling the contact mass withdrawn from step 4 to step 1 and (6) recovering the phosgene from the separate reaction zone.

7. The process as described in claim 6 wherein the carrier is activated alumina.

8. The process as described in claim 6 wherein the contact mass of step 1 comprises a porous refractory solid impregnated with a mixture of cuprous chloride. cupric chloride and potassium chloride.

9. A continuous process for the manufacture of phosgene from hydrogen chloride, carbon monoxide and oxygen which comprises (1) introducing a contact mass comprising cuprous chloride supported on a nely divided porous refractory carrier into a first reaction zone at a temperature between about 320 C. and about 345 C.. (2) contacting the supported cuprous chloride in the first reaction zone with oxygen by suspending the carrier in an upflowing stream of an oxygen containing gas under hindered settling conditions to convert at least a portion of the cuprous chloride to cupric oxychloride, (3) continuously removing a portion of the contact mass containing cupric oxychloride without intermediate cooling and introducing it into a second separate reaction zone. (4) contacting the mass in the second reaction zone with a mixture of oxygen and hydrogen chloride by suspending the powdered carrier in an upowing stream of a mixture of engen containing gas and hydrogen chloride under hindered settling conditions to convert additional cuprous chloride to cupric oxychloride and to convert the cupric oxychloride thereinto cupric chloride while controlling the exothermic reaction to prevent the temperature from exceeeding 525 C., (5) continuously withdrawing a portion of the contact mass containing thecupric chloride and transferring it directly without intermediate cooling to a third reaction zone, (6) contacting the mass in the third reaction zone with carbon monoxide by suspending the powdered carrier in an upowing stream of gaseous carbon monoxide under hindered settling conditions to form phosgene and to reduce at least a portion of the cupric chloride to cuprous chloride while maintaining a tempera- REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,511,646 Weaver Oct. 14, 1924 1,915,618 Ralston et al June 27, 1933 FOREIGN PATENTS Number Country Date 214,293 Great Britain Apr. 14, 1924 OTHER REFERENCES Gobel: Journal fr praktische Chemie (1835), vol. 6, pages 387-388.

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